Polymer nanocomposites for air movement devices

ABSTRACT

In one embodiment, the invention provides an air movement device having a matrix polymer and nanoparticles. In another embodiment, the invention provides a method of manufacturing an air movement device having dry-mixing about 30% to about 80% by weight matrix polymer and about 2% to about 15% by weight layered clay to form a dry mixture, extruding the mixture to form a polymer nanocomposite, and molding the polymer nanocomposite into an air movement device. In yet another embodiment, the invention provides an air movement device having about 30% to about 80% by weight polypropylene, about 3% to about 10% by weight layered clay, and about 1% to about 10% by weight maleic anhydride grafted polystyrene, wherein the air movement device has a UL 94 5VA flame retardant rating.

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Patent Application No. 60/560,177 filed Apr. 7, 2004, theentire content of which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to air movement devices used in HeatingVentilation and Air Conditioning (HVAC) systems. Specifically, theinvention relates to materials used to fabricate air movement devices inHVAC systems, such as axial and centrifugal fans, blower wheels, blowerhousings, orifices, plenum chambers, air-ducting, air diffusers andcondenser tops.

BACKGROUND OF THE INVENTION

Air movement devices are an integral component of HVAC systems and mustbe carefully designed to withstand the rigorous conditions under whichthey operate. The materials making up air movement devices must exhibithigh mechanical strength and demonstrate good flame retardance and, insome cases, require a maximum UL-94 5VA rating. Since many of these airmovement devices are exposed to natural and artificial UV rays, theymust also be able to withstand degradation from UV radiation (naturaland artificial) during the useful life of the air movement device. Forthese reasons, air movement devices are typically made from metals, suchas steel and aluminum. However, metals are not without their drawbacks.For example, metal HVAC air movement devices cannot be easily and/orcost effectively fabricated into air foil geometries for air movementdevices that provide the most efficient air movement in HVAC systems. Anattempt was made several years ago to design plastic air movementdevices for residential and commercial, but the industry failed toembrace the concept after some of these air movement devices failed frommechanical fatigue, UV exposure and exposure to synthetic agents.Therefore, a need currently exists within the HVAC industry for amaterial that can be easily fabricated into a variety of air movementgeometries that can improve sound, air-flow and efficiencies, and can beeconomically produced to meet the performance standards of HVAC systems.

SUMMARY OF THE INVENTION

In one embodiment, the invention provides an air movement device havinga matrix polymer and nanoparticles.

In another embodiment, the invention provides a method of manufacturingan air movement device having dry-mixing about 30% to about 80% byweight matrix polymer and about 2% to about 15% by weight layered clayto form a dry mixture, extruding the mixture to form a polymernanocomposite, and molding the polymer nanocomposite into an airmovement device.

In yet another embodiment, the invention provides an air movement devicehaving about 30% to about 80% by weight polypropylene, about 3% to about10% by weight layered clay, and about 1% to about 10% by weight maleicanhydride grafted polystyrene, wherein the air movement device has a UL94 5VA flame retardant rating.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a 3-bladed swept fan.

FIG. 2 shows a perspective view of a reversed inclined centrifugalblower wheel.

FIG. 3 shows a bottom perspective view of a condenser top with orificeand grill.

FIG. 4 shows a top perspective view of a condenser top with orifice andgrill.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items.

Polymer nanocomposites are a relatively new class of materials that havethe requisite physical and mechanical properties necessary torevolutionize the fabrication of air movement devices in the HVACindustry, such as axial and centrifugal fans, blower wheels, blowerhousings, orifices, plenum chambers, air-ducting, air diffusers andcondenser tops. Polymer nanocomposites are typically made by dispersingnanoparticles within one or more matrix polymers. A concentration ofnanoparticles as low as 1% can improve the physical properties of thematrix polymer by as much as 10%. Air movement devices made from polymernanocomposites can benefit from at least one of increased solventresistance, enhanced flame retardant capability, increased resistance toUV radiation, and higher mechanical stability as demonstrated byincreased flex modulus, tensile strength and impact strength. Moreover,polymer nanocomposite air movement devices can be manufactured into anynumber of shapes through injection molding, blow molding, extrusion orother such molding techniques, thus allowing the industry to design moreenergy efficient shapes and geometries that can result in increased airflow (CFM) as well as overall sound reduction (DBA) and provide costeffective air movement devices comparable with metal fabricated airmovement devices as currently available today.

Matrix Polymers

Any polymer or oligomeric resin having the necessary physical propertiesto permit dispersal of nanoparticles may qualify as a matrix polymer.Matrix polymers typically make up globally greater than about 1% byweight, more particularly greater than about 20% by weight, and evenmore particularly greater than about 40% by weight polymernanocomposite. Matrix polymers typically make us less than about 99% byweight, more particularly less than about 80% by weight, and even moreparticularly less than about 60% by weight polymer nanocomposite.Illustrative matrix polymers include, but are not limited to,homopolymers and copolymers of the following: polyesters,polyetheresters, polyamides, polyesteramides, polyurethanes, polyimides,polyetherimides, polyureas, polyamideimides, polyphenyleneoxides,phenoxy resins, epoxy resins, polyolefins, polyacrylates, polystyrenes,polyethylene-co-vinyl alcohols, and the like or their combinations andblends. Matrix polymers may be linear, branched, star, cross-linked anddendritic structures. The matrix polymers are preferably polyolefins andpolyamides.

Polyolefin matrix polymers may include, but are not limited to,polyethylene, polypropylene, ethylene-vinyl acetate,poly(4-methylpentene-1), poly(styrene-co-butadiene), cyclobutene, andthe like or their combinations and blends. Exemplary disclosures ofpolyolefins are found in U.S. Pat. No. 6,632,868 issued Oct. 14, 2003,which is hereby fully incorporated by reference. In one embodiment, thepolyolefin matrix polymer is a homopolymer or copolymer ofpolypropylene.

Polyamide matrix polymers may include the products resulting from thepolycondensation polymerization reaction between a diamine anddicarboxylic acid, the self-condensation of amino acids and/or theirderivatives, and/or ring opening polymerization of lactams. Polyamidesmay include, but are not limited to, poly(m-xylylene adipamide),poly(m-xylylene adipamide-co-isophthalamide), poly(hexamethyleneisophthalamide), poly(hexamethylene isophthalamide-co-terephthalamide),poly(hexamethylene adipamide-co-isophthalamide), poly(hexamethyleneadipamide-co-terephthalamide), poly(hexamethyleneisophthalamide-co-terephthalamide), poly(hexamethylene adipamide),poly(caprolactam), polycarpramide (nylon-6), poly-aminoheptanoic acid(nylon-7), poly-aminonanoic acid (nylon 9), polyundecane-amide(nylon-11), polyaurylactam (nylon-12), poly(ethylene-adipamide)(nylon-2,6), poly(tetramethylene-adipamide) (nylon-4,6),poly(hexamethylene-adipamide) (nylon-6,6),poly(hexamethylene-sebacamide) (nylon-6,10),poly(hexamethylene-dodecamide) (nylon-6,12),poly(octamethylene-adipamide) (nylon 8,6), poly(decamethylene-adipamide)(nylon-10,6), poly(dodecamethylene-adipamide) (nylon 12,6),poly(dodecamethylene-sebacamide) (nylon-12,8), and the like or theircombinations and blends. Exemplary disclosures of polyamides are foundin U.S. Pat. No. 6,586,500 issued Jul. 1, 2003, which is hereby fullyincorporated by reference. Preferably, the polyamide matrix polymercomprises Nylon-6.

Additives

Additives may optionally be added to the matrix polymer to impart avariety of properties to the polymer nanocomposite. Almost any additivesuitable for use with the neat polymer may be applicable here as well.Additives typically make up greater than about 1% by weight, moreparticularly greater than about 10% by weight, and even moreparticularly greater than about 20% by weight polymer nanocomposite.Additives typically make up less than about 70% by weight, moreparticularly less than about 50% by weight, and even more particularlyless than about 40% by weight polymer nanocomposite. Additives mayinclude, but are not limited to, colorants, pigments, toners, carbonblack, glass fibers, fillers, impact modifiers, antioxidants, surfacelubricants, denesting agents, UV light absorbing agents, metaldeactivators, fillers, nucleating agents, stabilizers, compatibalizers,flame retardants, reheat aids, crystallization aids, acetaldehydereducing compounds, recycling release aids, oxygen scavengers,plasticizers, nucleators, mold release agents, compatibilizers, and thelike. Examples of additives include, but are not limited to, brominatedpolystyrene, polybrominated diphenyl oxides, antimony oxide, and maleicanhydride modified polymers, such as maleic anhydride graftedpolystyrene.

Nanoparticles

Nanoparticles are defined as any particle having at least one dimensionin the nanometer range which enhances the properties of a matrix polymerwhen dispersed throughout. Nanoparticles typically make up greater thanabout 1% by weight, more particularly greater than about 3% by weight,and even more particularly greater than about 10% by weight polymernanocomposite. Nanoparticles typically make up less than about 99% byweight, more particularly less than about 50% by weight, and even moreparticularly less than about 20% by weight polymer nanocomposite. In oneembodiment of the invention, the nanoparticles include layered clays.

Layered clays are natural or synthetic inorganic materials having aplurality of adjacent bound layers. In one embodiment, as illustrated bythe naturally-occurring clays bentonite or hectorite, the layered claycomprises negatively charged sheets stacked on top of each other andseparated by an interlamellar region containing charge-balancingcations, such as alkali metal ions, alkaline earth metal ions, andammonium ion. The sheets preferably have a thickness of less than 2 nmand a diameter in the range of about 10 to about 5000 nm. Theinterlamellar spacing is variable but typically greater than 0.3 nm. Ina polymer nanocomposite, at least a portion of the sheets are separated(exfoliated) and homogeneously dispersed within the polymer matrix. Thenanoscale size of the sheets imparts the nanoscopic properties to thepolymer nanocomposite.

Examples of layered clays include, but are not limited to, the smectiteclays such as montmorillonite, saponite, hectorite, mica, vermiculite,bentonite, nontronite, beidellite, volkonskoite, magadite, and kenyaite.In one embodiment, the layered clay comprises montmorillonite. Suitablelayered clays are available from various companies including Nanocor,Inc. of Arlington Heights, Ill., Southern Clay Products of Gonzales,Tex., Kunimine Industries, Ltd. of Tokyo, Japan, and Rheox Inc. ofHightstown, N.J.

Layered clays may be treated to facilitate dispersion of the sheetswithin the matrix polymer. Treatment typically involves modifying thelayered clays so that oligomers and polymers can more easily intercalate(i.e. penetrate) into the interlamellar region between the layers andultimately aid in dispersing the individual layers throughout the matrixpolymer. A variety of treatments are disclosed in U.S. patentapplication Ser. Nos. 10/072,759 filed on Feb. 8, 2002 and 10/874,774filed on Jun. 23, 2004, each of which is hereby fully incorporated byreference and U.S. Pat. No. 6,586,500. Treatments are also disclosed inU.S. Pat. No. 6,632,868. A brief description of some of these treatmentsis provided below.

The edges of clay layered material may contain —OH groups that tend toinhibit intercalation of non-polar and low polarity oligomers andpolymers into the layered clay. One form of treatment, therefore, is toreact the —OH groups at the edges of the clay sheets with a less polarcoupling agent to provide an environment more conducive to intercalationof non-polar and less polar oligomers and polymers. Useful couplingagents are disclosed in U.S. Pat. No. 6,632,868 and are selected fromthe group consisting of silanes, titanates, aluminates, zirconates, andmixtures thereof, particularly the organosilanes, organotitanate,organoaluminates and/or organozirconates. The coupling agent can beadded to dry onium-intercalated clay, added to a water slurry ofonium-intercalated clay followed by separation and drying of the clay,or added to the polymer either before or after introduction of theonium-intercalated clay.

A second method of treatment is to replace the cations in theinterlamellar region with organic cations. The organic cations provide aless polar interlamellar region that facilitates intercalation of thenon-polar and the less polar oligomers and polymers. Additionally, theorganic cations are typically larger than the metal ions and ammoniumions they replace, thus increasing the distance between the layers andmaking it easier to shear the layers (i.e., exfoliate the clay).

Organic cations refer to any positively charged ion having at least onecarbon atom bonded to hydrogen or another carbon atom. The cation maycontain any heteroatom in the periodic table, and the charge may, andtypically does, rest on an atom other than carbon. Organic cationsinclude organometallic cations, such as ferrocenium cations and/or theirderivatives. More preferably, organic ions include onium ions having apositively-charged nitrogen, phosphorus, sulfur, or oxygen atom, inaddition to at least one carbon atom. The organic cation is normallyaccompanied by a charge-balancing anion such as a halide, a hydroxide, acarbonate, an alkoxide, a carboxylate, a phosphate, a silicate and anacetate.

Examples of organic cations that may be used to treat layered clays aredisclosed in U.S. Pat. Nos. 6,632,868 and 6,586,500 and U.S. patentapplication Ser. No. 10/072,759 and include, but are not limited to:alkyl ammonium ions such as tetramethyl ammonium, hexyl ammonium, butylammonium, bis(2-hydroxyethyl) dimethyl ammonium, hexyl benzyl dimethylammonium, benzyl trimethyl ammonium, butyl benzyl dimethyl ammonium,tetrabutyl ammonium, di(2-hydroxyethyl) ammonium, dodecyl ammonium,octadecyl trimethyl ammonium, bis(2-hydroxyethyl) methyl tallowammonium, bis(2-hydroxyethyl) methyl hydrogenated tallow ammonium,octadecyl benzyl dimethyl ammonium; alkyl phosphonium ions such astetrabutyl phosphonium, trioctyl octadecyl phosphonium, tetraoctylphosphonium, octadecyl triphenyl phosphonium; alkoxylated ammoniumcompounds such as mono-alkoxylated, di-alkoxylated, tri-alkoxylated,tetra-alkoxylated ammonium compounds, wherein the alkoxylated groupcomprises at least one alkyleneoxide group having from 2 to 6 carbonatoms and the alkoxylate groups may be hydroxyalkygroups, having atleast one terminal hydroxyl (—OH) group bound to any one of the carbonatoms; di-alkoxylated ammonium compounds such as bis(2-hydroxymethyl)octadecyl ammonium, bis(2-hydroxyethyl) octadecylmethyl ammonium,octadecylisopropoxydimethyl ammonium; and, polyalkoxylated ammoniumcompounds such as the hydrochloride salts of polyalkoxylated amines suchas JEFFAMINE (of Huntsman Chemical), namely, JEFFAMINE-506 andJEFFAMINE-505, and ETHOMEEN (of Akzo Chemie America), namely, ETHOMEEN18/25, which is octadecyl bis(polyoxyethylene[15])amine, and ETHOQUAD18/25 (of Akzo Chemie America), which is octadecyl methylbis(polyoxyethylene[15]) ammonium chloride. An additional exampleincludes amino dodecanoic acid.

Numerous methods for intercalating organic cations into layered claysare known. In one embodiment, organic cations are added to an aqueousslurry of the layered clay having a temperature range of about 50-80° C.The mixture of organic cation and layered clay is stirred at theelevated temperature for a period of time sufficient for the organiccations to exchange out the metal ions in the interlamellar region ofthe clay. The new organically modified clay is then separated from theslurry by any number of techniques that include filtration,centrifugation, spray drying, and their combination.

A third method involves intercalating the layered clay with a polyolefinintercalant and a maleic anhydride-modified polyolefin intercalant toform a concentrate. The concentrate can be dispersed in the matrixpolymer and optionally exfoliated prior to adding more matrix polymer.Exfoliation is accomplished by shearing the layered clay by anyappropriate method that includes, but is not limited to, mechanicalmeans (extrusion), by chemical means, by thermal shock, by pressurealteration, or by ultrasonics. Shearing prior to adding more matrixpolymer avoids degrading the polymer during the shearing action.

Other treatment methods which modify the clay for the purpose offacilitating dispersion within the matrix polymer are known to thoseskilled in the art and disclosed in U.S. Pat. Nos. 6,586,500 and6,632,868 and U.S. patent application Ser. Nos. 10/874,774 and10/072,759. Layered clays may be treated using a single method or acombination of methods applied in any order. Treatment of a layered claycan be done prior to the addition of matrix polymer to the claymaterial, during the dispersion of the clay material within the matrixpolymer, or during a subsequent melt blending or melt fabrication step.Examples of commercially treated clays include Cloisite® 10A, Cloisite®15A, Cloisite® 20A, Cloisite® 25A and Cloisite® 90A from Southern ClayProducts of Gonzales, Tex.

Preparation of Polymer Nanocomposite

Processes to prepare polymer nanocomposites are known to those skilledin the art and disclosed in U.S. patent application Ser. No. 10/105,618filed on Mar. 26, 2002, which is hereby fully incorporated by referenceand U.S. Pat. No. 6,586,500. In one embodiment, the followingingredients are combined to form a dry mixture: a matrix polymer,additives (optional), and layered clay, either treated, untreated, or acombination thereof. The layered clay and the matrix polymer may existas pellets, flakes, chips and powder. Additionally, the layered clay mayalso be reduced in size by methods known in the art, including, but notlimited to, grinding, pulverizing, hammer milling, jet milling, andtheir combination. Particle size may be less than about 100 nanometersin diameter, more particularly less than about 50 nanometers indiameter, and even more particularly less than about 20 nanometers indiameter. Layered clays are preferably 3 to 25 nanometers in diameter.The dry mixture is then passed through a compounding extruder underconditions sufficient to melt the polymer and form the nanocomposite.

In an alternative embodiment, the individual ingredients can be fedseparately into a compounding extruder. A compatibalizer is typicallyadded to facilitate dispersion of the layered clay within the matrixpolymer.

In yet another embodiment, a treated or untreated clay is dispersed in apolymerizable liquid monomer that may or may not contain additives.Polymerization may be effected by UV light, acid, base, or heat.

Molded articles such as air movement devices, blower wheels, blowerhousing, orifices, plenum chambers, air-ducting, air diffusers, andcondenser tops can be molded from the polymer-nanocomposites byinjection molding, blow molding, extrusion, or other such moldingtechniques, all of which are known in the art.

Polymer nanocomposite air movement devices of the present invention mayhave tensile strength values in the range of about 3500 psi to about3650 psi, flex modulus values in the range of about 265,000 psi to about280,000 psi, Izod impact values in the range of about 0.5 ft·lbs/in toabout 0.7 ft·lbs/in, and heat deflection temperature (HDT) values in therange of about 55° C. to about 60° C.

EXAMPLES

The following examples and experimental results are included to providethose of ordinary skill in the art with a complete disclosure anddescription of particular manners in which the present invention can bepracticed and evaluated, and are not intended to limit the scope of theinvention.

Examples 1-2 illustrate two embodiments of a polypropylenenanocomposite. Polypropylene pellets from Huntsman of Salt Lake City,Utah, Cloisite® 20A from Southern Clay Products, Inc. of Gonzales, Tex.,decabromo diphenyl oxide, and antimony oxide were combined in theamounts indicated below to form a dry mixture. The mixture in Example 1was passed through the extruder once to form the polypropylenenanocomposite (i.e., one compound pass). The mixture in Example 2 waspassed through the extruder twice prior to forming the polypropylenenanocomposite (i.e., twice compounding pass). Although these sampleswere molded for testing purposes, the same material may be fabricatedinto air movement devices, such as blower wheels, blower housing,orifices, plenum chambers, air-ducting, air diffusers, and condensertops.

Physical data for the two samples is provided below. Tensile strengthwas measured according to ASTM D638-02a Standard Test Method for TensileProperties of Plastics, where the speed was 2.0 in/min and the gaugelength was 2.0 inches. Elongation was determined according to ASTM D638.Flex Modulus was measured according to ASTM D790-02 Flexural Propertiesof Plastics, where the speed was 0.05 in/min and the gauge span was 2.0inches. Specific gravity was measured according to ASTM D792-00 Densityand Specific Gravity. Izod impact was measured according to ASTMD256-A-02 Room Temperature Izod Impact. Heat deflection temperature(HDT) was measured according to ASTM D648-01 Heat DeflectionTemperature, where the load was 264 psi and the rise of heat was 120°C./hr. The flammability was determined using the UL 94 Flammability Testthat met the 5VA test requirements.

Examples 1-2

Example 1 Example 2 Polypropylene 65.444% 65.444% Cloisite ® 20A  4.000% 4.000% Decabromo Diphenyl Oxide 25.000% 25.000% Antimony Oxide  5.556% 5.556% Compounding Pass Once Twice Tensile Strength (psi) 3586 3613Elongation (%) 4.64 5.04 Flex Modulus (psi) 269368 278152 SpecificGravity 1.12 1.12 Izod Impact (ft·lbs/in) 0.5 0.5 HDT (° C.) 55 58Flammability No Burn No Burn

Examples 3-8

Examples 3-8 illustrate six embodiments of a Nylon-6 nanocomposite.Nylon-6, Cloisite® 20A from Southern Clay Products, Inc. of Gonzales,Tex., maleic anhydride modified polystyrene, brominated polystyrene, andantimony oxide were combined in the amounts indicated below to form adry mixture. The mixture was then compounded through a twin screwextruder to form the Nylon-6 nanocomposite. Samples compounded at hightemperature exited the extruder at 190° C. Samples compounded at lowtemperature exited the extruder at 170° C. Although these samples weremolded for testing purposes, the same material may be fabricated intoair movement devices, such as blower wheels, blower housing, orifices,plenum chambers, air-ducting, air diffusers, and condenser tops.

Physical data was analyzed using the methods of Examples 1-2. Example 3Example 4 Example 5 Nylon-6 60.220% 69.545% 67.670% Cloisite ® 20A 4.000%  4.620%  4.495% Maleic Anhydride Modified  1.835%  1.835% 1.835% Polystyrene Brominated Polystyrene 27.523% 19.460% 21.080%Antimony Oxide  6.422%  4.540%  4.920 Processing Temperature High HighHigh Temperature Temperature Temperature Flex Modulus (psi) 599372540735 553179 Izod Impact (ft·lbs/in) 0.47 0.47 0.5 Flammability No BurnUnavailable Unavailable Example 6 Example 7 Example 8 Nylon-6 65.794%65.794% 64.857% Cloisite ® 20A  4.371%  4.371%  4.308% Maleic AnhydrideModified  1.835%  1.835%  1.835% Polystyrene Brominated Polystyrene22.7000% 22.7000% 23.510% Antimony Oxide  5.300%  5.300%  5.490%Processing Temperature High Low High Temperature Temperature TemperatureFlex Modulus (psi) 566547 565264 566942 Izod Impact (ft·lbs/in) 0.55 0.50.47 Flammability Unavailable Unavailable No Burn

Prophetic examples are provided below.

Example 9

A Nylon-6 nanocomposite air movement device is fabricated by forming adry mix containing 68% (by wt.) Nylon-6, 5% (by wt.) Cloisite® 90A, 2%(by wt.) maleic anhydride grafted polystyrene, 5% (by wt.) antimonyoxide, and 20% (by wt.) brominated polystyrene in combination with anappropriate compatabilizer at 5% or less and passing the dry mix througha compounding extruder and into a mold having the shape of an airmovement device.

Example 10

A polypropylene nanocomposite air movement device is fabricated byforming a dry mix containing 70% (by wt.) polypropylene, 3% (by wt.)layered clay, 2% (by wt.) maleic anhydride grafted polystyrene, 5% (bywt.) antimony oxide, and 20% (by wt.) decabominated diphenyl oxide incombination with an appropriate compatabilizer at 5% or less and passingthe dry mix through a compounding extruder and into a mold having theshape of an air movement device.

Thus, the invention provides, among other things, air movement devicesin HVAC systems, including but not limited to, axial and centrifugalfans, blower wheels, blower housings, orifices, plenum chambers,air-ducting, air diffusers and condenser tops fabricated fromnanoparticles and one or more matrix polymers. Various features andadvantages of the invention are set forth in the following claims.

1. An air movement device comprising a matrix polymer and nanoparticles.2. The air movement device of claim 1, wherein the air movement devicecomprises at least one of axial fans, centrifugal fans, blower wheels,blower housings, orifices, plenum chambers, air-ducting, air diffusersand condenser tops.
 3. The air movement device of claim 1, wherein thematrix polymer comprises at least one of a polyester, a polyether ester,a polyamide, a polyesteramide, a polyurethane, a polyimide, apolyetherimide, a polyurea, a polyamideimide, a polyphenyleneoxide, aphenoxy resin, an epoxy resin, a polyolefin, a polyacrylate, apolystyrene, a polyethylene-co-vinyl alcohol, and a combination thereof.4. The air movement device of claim 1, wherein the matrix polymercomprises at least one of a polyolefin, a polyamide, a polyimide, and acombination thereof.
 5. The air movement device of claim 1, wherein thematrix polymer comprises polypropylene.
 6. The air movement device ofclaim 1, wherein the matrix polymer comprises Nylon-6.
 7. The airmovement device of claim 1, wherein the nanoparticles comprise at leastone of layered clays, carbon nanotubules, and chalcogens.
 8. The airmovement device of claim 1, wherein the nanoparticles comprise at leastone of montmorillonite, saponite, hectorite, mica, vermiculite,bentonite, nontronite, beidellite, volkonskoite, magadite, kenyaite, andcombinations thereof.
 9. The air movement device of claim 1, wherein thenanoparticles comprise montmorillonite.
 10. The air movement device ofclaim 1, wherein the polymer comprises a polyolefin and thenanoparticles comprise a layered clay.
 11. The air movement device ofclaim 1, wherein the polymer comprises polypropylene and thenanoparticles comprise montmorillonite.
 12. The air movement device ofclaim 1, wherein the polymer comprises a polyamide and the nanoparticlescomprise a layered clay.
 13. The air movement device of claim 1, whereinthe polymer comprises Nylon-6 and the nanoparticles comprisemontmorillonite.
 14. The air movement device of claim 1, furthercomprising at least one of brominated polystyrene, polybrominateddiphenyl oxide, and antimony oxide.
 15. The air movement device of claim1, further comprising maleic anhydride grafted polystyrene.
 16. The airmovement device of claim 1, wherein the air movement device comprisesabout 30% to about 80% by weight matrix polymer and about 2% to about15% by weight layered clay.
 17. The air movement device of claim 1,further comprising about 1% to about 10% by weight maleic anhydridegrafted polystyrene.
 18. The air movement device of claim 1, furthercomprising about 5% to about 15% by weight antimony oxide.
 19. The airmovement device of claim 1 having a UL 94 5VA flame retardant rating.20. The air movement device of claim 1 having a tensile strength valueof about 3500 psi to about 3650 psi.
 21. The air movement device ofclaim 1 having a flex modulus value of about 265,000 psi to about280,000 psi.
 22. The air movement device of claim 1 having an Izodimpact value of about 0.5 ft·lbs/in to about 0.7 ft·lbs/in.
 23. The airmovement device of claim 1 having a heat deflection temperature value ofabout 55° C. to about 60° C.
 24. A method of manufacturing an airmovement device comprising: dry-mixing about 30% to about 80% by weightmatrix polymer and about 2% to about 15% by weight layered clay to forma dry mixture; extruding the mixture to form a polymer nanocomposite;and molding the polymer nanocomposite into an air movement device. 25.The method of claim 24, wherein the air movement device comprises atleast one of axial fans, centrifugal fans, blower wheels, blowerhousings, orifices, plenum chambers, air-ducting, air diffusers andcondenser tops.
 26. The method of claim 24, wherein the layered clay hasbeen treated to facilitate dispersion in the matrix polymer.
 27. Themethod of claim 24, wherein the dry mixture further comprises at leastone of maleic anhydride modified polymer, decabrominated diphenyl oxide,polybrominated diphenyl oxide, antimony oxide, and combination thereof.28. An air movement device comprising: about 30% to about 80% by weightpolypropylene; about 3% to about 10% by weight layered clay; and about1% to about 10% by weight maleic anhydride grafted polystyrene, whereinthe air movement device has a UL 94 5VA flame retardant rating.